Manufacturing of Surface

layers
Layered Manufacturing vs. Conventional Manufacturing

• Subtractive
• Net shape
• Additive
Conventional Manufacturing
• Subtractive
– Start with simple stock
– Remove unwanted volume
– E.g. Machining
Manufacturing of surface layers
• Surface layers are formed before they are put into service.

• Object is subjected to a technological process, to create surface layers

• In some exceptional situations surface layers maybe formed during

service

• Layers can develop during low wear friction- service generated

surface layers
 Thermal

Thermo Thermo
Techniques
Mechanical Chemical Techniques for
of producing
surface manufacture
Electro of surface layers
Mechanical layers
Chemical
and Chemical

Physical
• Each technique allows obtaining a specific type of surface layer of
given thickness

• Surface layers maybe formed either with one technique or a

combination of technique’s
Mechanical

• The pressure of a tool or the kinetic energy

of a tool or particles.

• Strain hardening of superficial layer of a

metal or alloy at room temperature.

• Accomplished by burnishing (static or

dynamic), explosive spraying or machining
Shot peening- Dynamic burnishing
 Thermo mechanical
Use the combined effects of heat and
pressure to obtain coatings or
superficial layers

Some of the techniques used are

1. Thermal spraying
2. Plating
3. Explosive hardening
4. Plastic deformation
Mill Hot rolling
 Thermal
Effects connected with the influence of heat on materials

• Changing the microstructure of metallic materials in the solid state

• Transition from solid to liquid and again to solid of a metal material of

the substrate

• Obtaining a solid metal out of powdered coating material by melting

Thermo chemical techniques
These techniques use the combined effects of

1. Heat and medium chemically active material used with respect to

the treated metal- to saturate it with the given elements

2. Heat and chemical factors acting on the coating material in order to

harden it.
Electrochemical and Chemical
• In these two techniques several effects can be employed.

Deposit a metallic coating or

Either deposit or set a non metallic coating on a metallic surface

Polish, clean or pickle a metallic surface

They improve properties like corrosion resistance, wear resistance, and

physic-chemical ones like colour, lustre and reflectivity
Physical
• Production of organic coatings or metallic or ceramic coatings on the
surfaces of metals and nonmetals with adhesive or diffusion bonding
or creation of surface layers- makes use of various physical effects.

• These can occur under atmospheric pressure or lowered pressure in

the majority of cases with the participation of ions or elements of
metals or nonmetals.
 Surface engineering
techniques

Old generation techniques New generation techniques

Exclusively for Exclusively for

surface engineering Partially carrying out surface engineering Partially carrying out
tasks surface engineering tasks tasks surface engineering tasks

Enameling Heat Treatment Implantation Detonation

treatment Treatment
Plastic Glow discharge
Electroplating Spark discharge
deformation treatment treatment

Varnishing Casting CVD and PVD Electron Beam

techniques Treatment

Thermal Spraying Welding Sol Gel

techniques Laser Beam
Treatment
Burnishing Machining
Reference
Surface Engineering of Metals: Principles, Equipment, Technologies
By Tadeusz Burakowski, Tadeusz Wierzchon
https://books.google.co.in/books